Continuously variable transmission

ABSTRACT

Inventive embodiments are directed to components, subassemblies, systems, and/or methods for continuously variable transmissions (CVT). In one embodiment, a main axle is adapted to receive a carrier assembly to facilitate the support of components in a CVT. In another embodiment, a carrier includes a stator support member and a stator interfacial member. In some embodiments, the stator interfacial member is configured to interact with planet subassemblies of a CVT. Various inventive planet subassemblies and idler assemblies can be used to facilitate shifting the ratio of a CVT. In some embodiments, the planet subassemblies include legs configured to have a sliding interface with a carrier assembly. Embodiments of a hub shell, a hub cover are adapted to house components of a CVT and, in some embodiments, to cooperate with other components of the CVT to support operation and/or functionality of the CVT. Among other things, shift control interfaces and braking features for a CVT are disclosed.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/999,586, filed Mar. 23, 2011, which is a national phase applicationof International Application No. PCT/US2008/067940, filed Jun. 23, 2008.The disclosures of all of the above-referenced prior applications,publications, and patents are considered part of the disclosure of thisapplication, and are incorporated by reference herein in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The field of the invention relates generally to transmissions, and moreparticularly to continuously variable transmissions (CVTs).

2. Description of the Related Art

There are well-known ways to achieve continuously variable ratios ofinput speed to output speed. The mechanism for adjusting an input speedfrom an output speed in a CVT is known as a variator. In a belt-typeCVT, the variator consists of two adjustable pulleys having a beltbetween them. The variator in a single cavity toroidal-type CVT has twopartially toroidal transmission discs rotating about an axle and two ormore disc-shaped power rollers rotating on respective axes that areperpendicular to the axle and clamped between the input and outputtransmission discs.

Embodiments of the invention disclosed here are of the spherical-typevariator utilizing spherical speed adjusters (also known as poweradjusters, balls, sphere gears or rollers) that each has a tiltable axisof rotation; the speed adjusters are distributed in a plane about alongitudinal axis of a CVT. The speed adjusters are contacted on oneside by an input disc and on the other side by an output disc, one orboth of which apply a clamping contact force to the rollers fortransmission of torque. The input disc applies input torque at an inputrotational speed to the speed adjusters. As the speed adjusters rotateabout their own axes, the speed adjusters transmit the torque to theoutput disc. The input speed to output speed ratio is a function of theradii of the contact points of the input and output discs to the axes ofthe speed adjusters. Tilting the axes of the speed adjusters withrespect to the axis of the variator adjusts the speed ratio.

SUMMARY OF THE INVENTION

The systems and methods herein described have several features, nosingle one of which is solely responsible for its desirable attributes.Without limiting the scope as expressed by the claims that follow, itsmore prominent features will now be discussed briefly. After consideringthis discussion, and particularly after reading the section entitled“Detailed Description of Certain Inventive Embodiments” one willunderstand how the features of the system and methods provide severaladvantages over traditional systems and methods.

One aspect of the invention relates to a continuously variabletransmission having a group of balls that are arranged radially about alongitudinal axis. Each ball is configured to have a tiltable axis ofrotation. In one embodiment, a leg is operably coupled to each of theballs. The leg can be configured to tilt the axis of rotation of theball. The transmission can include a stator interfacial member slidinglycoupled to the leg. The transmission can also include a stator supportmember coupled to the stator interfacial member.

Another aspect of the invention concerns a transmission having a torquedriver rotatable about a longitudinal axis. The torque driver can beconfigured to receive a power input. The transmission can include atorsion plate operably coupled to the torque driver. The torsion platecan have a splined inner bore and a group of triangular extensionsextending radially from the splined inner bore. In one embodiment, thetransmission includes a load cam ring operably coupled to the torsionplate. The transmission can include a load cam roller retainer assemblyoperably coupled to the load cam ring. The transmission includes atraction ring operably coupled to the load cam roller retainer assembly.The transmission also includes a group of balls arranged radially abouta longitudinal axis. Each ball has a tiltable axis of rotation. Eachball can be operably coupled to the traction ring.

Yet another aspect of the invention involves a power input device thatincludes a torque driver rotatable about a longitudinal axis. The torquedriver can be configured to receive a power input. In one embodiment,the power input device includes a torsion plate coupled to the torquedriver. The torsion plate can have a splined inner bore and a number oftriangular extensions extending radially from the splined inner bore.The power input device can include a load cam ring coupled to thetorsion plate. In one embodiment, the power input device includes a loadcam roller retainer subassembly coupled to the load cam ring. The powerinput device can also include a traction ring coupled to the load camroller retainer subassembly.

One aspect of the invention concerns an assembly for an axial forcegenerator that includes a first slotted ring configured to receive anumber of load cam rollers. In one embodiment, the assembly includes asecond slotted ring configured to receive the load cam rollers. Theassembly can also include a spring configured to be retained in thefirst and/or second slotted ring.

Another aspect of the invention relates to a torsion plate having asubstantially disc-shaped body with a splined inner bore. In oneembodiment, the torsion plate has a number of structural ribs coupled tothe disc-shaped body. The structural ribs extend radially from thespline inner bore. The torsion plate can also have a set of splinescoupled to the outer periphery of the disc shaped body.

Yet one more aspect of the invention addresses a carrier for acontinuously variable transmission having a group of planetsubassemblies. Each planet subassembly has a ball configured to rotateabout a tiltable axis. In one embodiment, the carrier includes a statorinterfacial member configured to be operably coupled to a planetsubassembly. The carrier can include a stator support member operablycoupled to the stator interfacial member. The carrier can also include astator torque reaction member operably coupled to the stator supportmember.

In another aspect, the invention concerns a transmission having a groupof balls. Each ball is operably coupled to at least one leg. Thetransmission includes a stator interfacial member coupled to each leg.In one embodiment, the transmission includes a stator support membercoupled to the stator interfacial member. The transmission also includesa stator torque reaction member coupled to the stator support member.

Another aspect of the invention relates to a transmission having a groupof planet assemblies arranged angularly about a longitudinal axis of thetransmission. Each planet assembly has a leg. In one embodiment, thetransmission includes a stator interfacial member coaxial with thelongitudinal axis. The stator interfacial member has a number of radialgrooves configured to slidingly support the leg. The transmission alsoincludes a stator support member coupled to the stator interfacialmember. The stator support member is coaxial with the longitudinal axis.

One aspect of the invention relates to a stator assembly for acontinuously variable transmission. The stator assembly includes astator torque reaction insert having a number of torque reactionshoulders. In one embodiment, the stator assembly has a stator supportmember coupled to the stator torque reaction insert. The stator supportmember extends radially outward from the stator torque reaction insert.The stator support member can have a first face and a second face. Thestator assembly can also include a stator interfacial member coupled tothe stator support member. The stator interfacial member issubstantially supported by the first face of the stator support member.The stator interfacial member has a number of radial grooves.

Another aspect of the invention addresses a stator support member for acontinuously variable transmission (CVT). The stator support member caninclude a substantially disc-shaped body having an inner bore, a firstface and a second face. The stator support member can also have a groupof spacer support extensions arranged angularly on the first face. Inone embodiment, the stator support member includes a number of guidesupport slots. Each guide support slot is arranged substantially betweeneach of the spacer support extensions. The stator support member has anumber of interlocking holes formed in each of the guide support slots.The stator support member also has a number of capture extensions formedon the outer periphery of the disc-shaped body.

One more aspect of the invention concerns a stator interfacial memberfor a continuously variable transmission. The stator interfacial memberincludes a substantially disc-shaped body having a central bore, a firstface, and a second face. In one embodiment, the stator interfacialmember includes a number of sliding guide slots that extend radiallyfrom the central bore. The guide slots can be arranged substantially onthe first face. The stator interfacial member can include a set ofinterlocking tabs extending from the second face. The stator interfacialmember has a capture ring formed around the outer circumference of thedisc-shaped body. The stator interfacial member also has a group ofcapture cavities formed on the capture ring.

Yet another aspect of the invention involves a planet assembly for acontinuously variable transmission (CVT) having a shift cam and acarrier assembly. The planet assembly has a ball with a through bore. Inone embodiment, the planet assembly has a ball axle coupled to thethrough bore. The planet assembly also has a leg coupled to the ballaxle. The leg has a first end configured to slidingly engage the shiftcam. The leg further has a face configured to slidingly engage thecarrier assembly.

Another aspect of the invention relates to a leg for a continuouslyvariable transmission (CVT) having a carrier assembly. The leg includesan elongated body having a first end and a second end. In oneembodiment, the leg has an axle bore formed on the first end. The legcan have a shift cam guide surface formed on the second end. The shiftcam guide surface can be configured to slidingly engage a shift cam ofthe CVT. The leg can also have a sliding interface formed between thefirst end and the second end. The sliding interface can be configured toslidingly engage the carrier assembly.

Yet another aspect of the invention involves a transmission. In oneembodiment, the transmission includes a group of planet assembliesarranged angularly about, and on a plane perpendicular to, alongitudinal axis of the transmission. Each planet assembly has a leg.The transmission can include a set of stator interfacial insertsarranged angularly about the longitudinal axis. Each leg is configuredto slidingly couple to each of the stator interfacial inserts. Thetransmission can also include a stator support member mounted coaxiallywith the longitudinal axis. The stator support member can be configuredto couple to each of the stator interfacial inserts.

In another aspect, the invention concerns a stator support member for acontinuously variable transmission (CVT). The stator support memberincludes a generally cylindrical body having a central bore. In oneembodiment, the stator support member has a number of insert supportslots arranged angularly about, and extending radially from, the centralbore. The stator support member can include a number of stator supportextensions arranged coaxial with the insert support slots. The statorsupport extensions are arranged angularly about the central bore. Eachof the stator support extensions has a fastening hole and a dowel pinhole.

Another aspect of the invention relates to a planet assembly for acontinuously variable transmission (CVT) having a shift cam and acarrier assembly. The planet assembly includes a ball having a throughbore. In one embodiment, the planet assembly includes a ball axlereceived in the through bore. The planet assembly can also include a legcoupled to the ball axle. The leg has a first end configured toslidingly engage the shift cam. The leg has a face configured toslidingly engage the carrier assembly. The leg has an axle bore formedon a second end. The leg has a bearing support extension extending fromthe axle bore.

One aspect of the invention relates to a shift cam for a continuouslyvariable transmission (CVT). The shift cam has a number of leg contactsurfaces arranged angularly about, and extending radially from, alongitudinal axis of the CVT. Each of the leg contact surfaces has aconvex profile with respect to a first plane and a substantially flatprofile with respect to a second plane. The shift cam also has a shiftnut engagement shoulder formed radially inward of each of the legcontact surfaces.

Another aspect of the invention addresses a transmission having a groupof planet assemblies arranged angularly about a longitudinal axis. Eachplanet assembly has a leg. The transmission can have a statorinterfacial member operably coupled to each of the planet assemblies.The stator interfacial member can be coaxial with the group of planetassemblies. In one embodiment, the transmission has a stator supportmember coupled to the stator interfacial member. The stator supportmember includes a substantially bowl-shaped body having a central bore.The stator support member can have a fastening flange located on anouter periphery of the bowl-shaped body. The stator support member alsoincludes a set of interlocking tabs located on an interior surface ofthe bowl-shaped body. The interlocking tabs are configured to couple tothe stator interfacial member.

One more aspect of the invention concerns a stator support member for acontinuously variable transmission having a stator interfacial member.In one embodiment, the stator support member has a substantiallybowl-shaped body with a central bore. The stator support member includesa fastening flange located on an outer periphery of the bowl-shapedbody. The stator support member also has a set of interlock tabs locatedon an interior surface of the bowl-shaped body.

Yet another aspect of the invention involves a stator interfacial memberfor a continuously variable transmission (CVT). The stator interfacialmember includes a substantially disc-shaped body with an inner bore, afirst face, and a second face. In one embodiment, the stator interfacialmember has a number of guide slots arranged angularly about, andextending radially from the inner bore. The guide slots are formed onthe first face. The stator interfacial member includes a set ofinterlock tabs substantially aligned with each of the guide slots. Theinterlock tabs are formed on the second face. The stator interfacialmember can also include a number of stator support member extensionscoupled to each of the guide slots. The stator support member extensionsare located on an outer periphery of the disc-shaped body.

Another aspect of the invention relates to a transmission having a groupof planet assemblies arranged angularly about a longitudinal axis of thetransmission. Each planet assembly has a leg. In one embodiment, thetransmission includes an axle arranged along the longitudinal axis. Thetransmission can include a first stator support member slidingly coupledto each of the planet assemblies. The first stator support member has afirst central bore. The first central bore can be coupled to the axle.The transmission includes a second stator support member sliding coupledto each of the planet assemblies. The second stator support member has asecond central bore. The second central bore has a diameter larger thana diameter of the first central bore. The transmission can also includea set of stator spacers coupled to the first and second stator supportmembers. The stator spacers are arranged angularly about thelongitudinal axis.

Yet one more aspect of the invention addresses a stator support memberfor a continuously variable transmission (CVT). The stator supportmember has a generally disc-shaped body having a central bore. In oneembodiment, the stator support member has a group of support extensionsarranged angularly about the central bore. Each of the supportextensions has a substantially triangular shape. Each of the supportextensions is located radially outward of the central bore. The statorsupport member includes a number of stator spacer cavities coupled tothe support extensions. The stator spacer cavities have a substantiallytriangular shape. The stator support member can also include a number ofguide slots formed on the disc-shaped body. Each guide slot extendsradially from the central bore. Each guide slot is substantiallyangularly aligned with each of the support extensions.

In another aspect, the invention concerns a stator spacer for acontinuously variable transmission. The stator spacer includes anelongated body having a first end and a second end. In one embodiment,the stator spacer has a clearance neck formed between the first end andthe second end. Each of the first and second ends has a substantiallytriangular cross-section. At least a portion of the clearance neck has asubstantially diamond-shaped cross-section.

Another aspect of the invention relates to an idler assembly for acontinuously variable transmission (CVT). The idler assembly includes asubstantially cylindrical idler having a central bore. The central boredefines a longitudinal axis. The idler is configured to rotate about thelongitudinal axis. In one embodiment, the idler assembly includes firstand second shift cams operably coupled respectively to a first and asecond end of the idler. The first and second shift cams are configuredto be substantially non-rotatable about the longitudinal axis. The idlerassembly includes a first shift nut coupled to the first shift cam. Thefirst shift nut has a threaded bore and a shift cam engagement shoulderextending radially from the threaded bore. The idler assembly alsoincludes a second shift nut coupled to the second shift cam, the secondshift nut comprising a second threaded bore and a second shift camengagement shoulder extending radially from the second threaded bore.

One aspect of the invention relates to a method of manufacturing anidler assembly for a continuously variable transmission (CVT) having anaxle arranged along a longitudinal axis. In one embodiment, the methodincludes providing a shift nut clearance slot in the axle. The methodcan include providing a substantially cylindrical idler having a centralbore. The method includes operably coupling the idler to a first shiftcam on a first end of the idler and to a second shift cam on a secondend of the idler thereby yielding a subassembly including the idler, thefirst shift cam, and the second shift cam. The method includes placing ashift nut in the shift nut clearance slot. The shift nut has a shift camengagement shoulder extending radially from a threaded bore. The methodincludes installing the subassembly of the idler, the first shift cam,and the second shift cam on the axle such that said subassemblysubstantially surrounds the shift nut. The method also includes couplinga shift rod to the threaded bore of the shift nut thereby coupling theshift nut engagement shoulder to the first or second shift cam.

Another aspect of the invention concerns a hub shell for a continuouslyvariable transmission (CVT). The hub shell includes a generally hollowcylindrical body having a substantially closed end and a central bore.In one embodiment, the hub shell has first and a second spoke flangescoupled to an outer periphery of the hollow cylindrical body. The hubshell includes a set of brake splines coupled to the substantiallyclosed end. The hub shell can have a locking chamfer coupled to thesubstantially closed end. The locking chamfer is located radiallyoutward of, and coaxial with the brake splines. The hub shell can alsoinclude a set of splines coupled to the substantially closed end. Thesplines are located on an interior surface of the cylindrical body.

Yet another aspect of the invention involves a brake adapter kit for acontinuously variable transmission (CVT) having a hub shell. The brakeadapter kit includes a brake adapter ring having a brake alignmentsurface. The brake adapter ring has a locking chamfer configure toengage the hub shell. The brake adapter kit can include a roller brakeadapter configured to couple to the brake adapter ring and to the hubshell. Once assembled the roller brake adapter is rigidly coupled to thehub shell.

One aspect of the invention concerns a brake adapter kit for acontinuously variable transmission (CVT) having a hub shell. The brakeadapter kit includes a brake adapter ring having a brake alignmentsurface. The brake adapter ring has a locking chamfer configure toengage the hub shell. In one embodiment, the brake adapter kit includesa disc brake adapter configured to couple to the brake adapter ring andto the hub shell. Once assembled the disc brake adapter is rigidlycoupled to the hub shell.

Another aspect of the invention relates to a transmission having a groupof planet assemblies arranged angularly about a longitudinal axis of thetransmission. Each planet assembly has a leg. In one embodiment, thetransmission includes a stator interfacial cap coupled to each leg. Thetransmission includes a stator support member coaxial with the planetassemblies. The stator support member has a number of guide groovesarranged angularly about, and extending radially from, the longitudinalaxis. Each of the stator interfacial caps is configured to engageslidingly to the stator support member.

Yet one more aspect of the invention addresses a planet assembly for acontinuously variable transmission. The planet assembly can include aball with a through bore. The planet assembly includes an axle operablyreceived in the through bore. The axle can be configured to provide atiltable axis of rotation for the ball. In one embodiment, the planetassembly includes a leg coupled to the axle. The leg has an elongatedbody with a first end and a second end. The leg couples to the axle inproximity to the first end. The planet assembly also includes a statorinterfacial cap coupled to the leg. The stator interfacial cap has asliding interfacial surface.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of one embodiment of a bicycle having acontinuously variable transmission (CVT) in accordance with inventiveembodiments disclosed herein.

FIG. 2 is a partially cross-sectioned, perspective view of oneembodiment of a (CVT).

FIG. 3 is a cross-sectional view of the CVT of FIG. 2.

FIG. 4 is a perspective, cross-sectional view of one embodiment of aninput subassembly that can be used in the CVT of FIG. 2.

FIG. 5 is a perspective view of a torque driver that can be used in theinput subassembly of FIG. 4.

FIG. 6 is a cross-sectional view of the torque driver of FIG. 5.

FIG. 7 is a perspective view of a torsion plate that can be used in theinput subassembly of FIG. 4.

FIG. 8 is a cross-sectional view of the torsion plate of FIG. 7.

FIG. 9 is a perspective view of a load cam ring that can be used in theinput subassembly of FIG. 4.

FIG. 10 is a cross-sectional view of the load cam ring of FIG. 9.

FIG. 11 is a perspective view of a traction ring that can be used in theinput subassembly of FIG. 4.

FIG. 12 is an exploded, perspective, cross-sectional view of certaincomponents of the CVT of FIG. 2.

FIG. 13, is a second exploded, perspective, cross-sectional view ofcertain of the components of FIG. 12.

FIG. 14 is a partial cross-section view of the components shown in FIG.12.

FIG. 15A is a perspective view of one embodiment of a torsion plate thatcan be used in the input subassembly of FIG. 4.

FIG. 15B is a partially cross-sectioned perspective view of the torsionplate of FIG. 15A.

FIG. 16A is a cross-sectional perspective view of a torsion plate andtraction ring that can be used with the CVT of FIG. 2.

FIG. 16B is an exploded cross-sectional perspective view of the torsionplate and traction ring of FIG. 16A.

FIG. 17 is a perspective view of one embodiment of an output load camthat can be used with the CVT of FIG. 2.

FIG. 18 is a block diagram showing one embodiment of a carrier assemblythat can be used with the CVT of FIG. 2.

FIG. 19 is an exploded, partially-cross-sectioned, perspective view ofthe CVT of FIG. 2 employing an embodiment of a carrier assembly.

FIG. 20 is a cross-sectional view of the carrier assembly of FIG. 20.

FIG. 21 is an exploded, partially cross-sectioned, perspective view ofone embodiment of a stator subassembly that can be used with the carrierassembly of FIG. 20.

FIG. 22 is a plan view of the stator subassembly of FIG. 21.

FIG. 23 is a second plan view of the stator subassembly of FIG. 21.

FIG. 24 is a cross-section of the stator subassembly of FIG. 21.

FIG. 25 is a perspective view of one embodiment of a stator supportmember that can be used with the stator subassembly of FIG. 21.

FIG. 26 is a second perspective view of the stator support member ofFIG. 26.

FIG. 27 is a partially cross-sectioned, perspective view of a statorinterfacial member that can be used with the stator subassembly of FIG.21.

FIG. 28 is a perspective view of one embodiment of a planet subassemblythat can be used in the CVT of FIG. 2.

FIG. 29 is a cross-sectional view of the planet subassembly of FIG. 28.

FIG. 30 is a perspective view of one embodiment of a leg that can beused with the planet subassembly of FIG. 28.

FIG. 31 is a cross-sectional view of the leg of FIG. 30.

FIG. 32 is a cross-sectional view of one embodiment of a leg that can beused with the planet subassembly of FIG. 28.

FIG. 33 is an exploded, partially cross-sectioned, perspective view ofan embodiment of a carrier assembly that can be used with the CVT ofFIG. 2.

FIG. 34 is a cross-sectional view of the carrier assembly of FIG. 33.

FIG. 35 is a perspective view of one embodiment of a stator supportmember that can be used with the carrier assembly of FIG. 33.

FIG. 36 is a partially cross-sectioned, perspective view of the statorsupport member of FIG. 35.

FIG. 37 is a plan view of the stator support member of FIG. 35.

FIG. 38 is a second plan view of the stator support member of FIG. 35.

FIG. 39 is a perspective view of one embodiment of a stator interfacialinsert that can be used with the carrier assembly of FIG. 33.

FIG. 40 is a second perspective view of the stator interfacial insert ofFIG. 39.

FIG. 41 is a cross-sectional view of the stator interfacial insert ofFIG. 39.

FIG. 42 is a cross-sectional view of an embodiment of a statorinterfacial insert that can be used with the carrier assembly of FIG.33.

FIG. 43 is a partially cross-sectioned, exploded, perspective view of anembodiment of a carrier assembly that can be used with the CVT of FIG.2.

FIG. 44 is a cross-sectional view of the carrier assembly of FIG. 43.

FIG. 45 is a perspective view of one embodiment of a stator supportmember that can be used in the carrier assembly of FIG. 43.

FIG. 46 is a second perspective view of the stator support member ofFIG. 45

FIG. 47 is a perspective view of one embodiment of a planet subassemblythat can be used with the carrier assembly of FIG. 43.

FIG. 48 is a cross-sectional view of the planet subassembly of FIG. 47.

FIG. 49 is a partially cross-sectioned, perspective view of oneembodiment of a shift cam that can be used in the CVT of FIG. 2.

FIG. 50 is a cross-sectional view of the shift cam of FIG. 49.

FIG. 51 is a partially cross-sectioned, exploded, perspective view of anembodiment of a carrier assembly that can be used in the CVT of FIG. 2.

FIG. 52 is a cross-sectional view of the carrier assembly of FIG. 51.

FIG. 53 is a perspective view of a stator support member that can beused in the carrier assembly of FIG. 51.

FIG. 54 is a second perspective view of the stator support member ofFIG. 53.

FIG. 55 is a perspective view of one embodiment of a stator interfacialmember that can be used in the carrier assembly of FIG. 51.

FIG. 56 is a second perspective view of the stator interfacial member ofFIG. 55.

FIG. 57 is a partially cross-sectioned, exploded, perspective view of anembodiment of a carrier assembly that can be used in the CVT of FIG. 2.

FIG. 58 is a cross-sectional view of the carrier assembly of FIG. 57.

FIG. 59 is a perspective view of an embodiment of a stator supportmember that can be used in the carrier assembly of FIG. 57.

FIG. 60 is a perspective view of an embodiment of a stator supportmember that can be used in the carrier assembly of FIG. 57.

FIG. 61 is a perspective view of an embodiment of a stator spacer thatcan be used in the carrier assembly of FIG. 57.

FIG. 62 is a cross-sectional view of the stator spacer of FIG. 61.

FIG. 63 is a perspective view of an embodiment of a main axle that canbe used in the CVT of FIG. 2.

FIG. 64 is a partially cross-sectioned, perspective view of a shift nutthat can be used in the CVT of FIG. 2.

FIG. 65A is a partially cross-sectioned, exploded, perspective view ofan embodiment of an idler assembly that can be used in the CVT of FIG.2.

FIG. 65B is a cross-section of the idler assembly of FIG. 65A.

FIG. 66 is a perspective view of an embodiment of a shift nut that canbe used in the idler assembly of FIG. 65A.

FIG. 67 is a perspective view of an embodiment of a hub shell that canbe used in the CVT of FIG. 2.

FIG. 68 is a second perspective view of the hub shell of FIG. 67.

FIG. 69 is a cross-sectional view of the hub shell of FIG. 67.

FIG. 70 is a perspective view of an embodiment of a hub cover that canbe used in the CVT of FIG. 2.

FIG. 71 is a second perspective view of the hub cover of FIG. 70.

FIG. 72 is a cross-sectional view of the hub cover of FIG. 70.

FIG. 73 is a perspective view of an embodiment of a brake adapter ringthat can be used with the CVT FIG. 2.

FIG. 74 is a cross-sectional view of the brake adapter ring of FIG. 73.

FIG. 75 is a perspective view of an embodiment of a disc brake adapterthat can be used with the CVT of FIG. 2.

FIG. 76 is a cross-section of the disc brake adapter of FIG. 75.

FIG. 77 is a perspective view of an embodiment of a roller brake adapterthat can be used with the CVT of FIG. 2.

FIG. 78 is a second perspective view of the roller brake adapter of FIG.77.

FIG. 79 is a cross-sectional view of the roller brake adapter of FIG.77.

FIG. 80 is a partially cross-sectioned, exploded, perspective view of anembodiment of a carrier assembly that can be used with the CVT of FIG.2.

FIG. 81 is a cross-sectional view of the carrier assembly of FIG. 80.

FIG. 82 is an exploded, perspective view of an embodiment of a planetsubassembly that can be used with the carrier assembly of FIG. 80.

FIG. 83 is an exploded, perspective view of certain components of theplanet subassembly of FIG. 82.

DETAILED DESCRIPTION OF CERTAIN INVENTIVE EMBODIMENTS

The preferred embodiments will be described now with reference to theaccompanying figures, wherein like numerals refer to like elementsthroughout. The terminology used in the descriptions below is not to beinterpreted in any limited or restrictive manner simply because it isused in conjunction with detailed descriptions of certain specificembodiments of the invention. Furthermore, embodiments of the inventioncan include several novel features, no single one of which is solelyresponsible for its desirable attributes or which is essential topracticing the inventions described. The CVT embodiments described hereare generally of the type disclosed in U.S. Pat. Nos. 6,241,636;6,419,608; 6,689,012; 7,011,600; 7,166,052; U.S. patent application Ser.Nos. 11/243,484; 11/543,311; 60/948,273; 60/864,941; and PatentCooperation Treaty Patent Application PCT/US2007/023315. The entiredisclosure of each of these patents and patent applications is herebyincorporated herein by reference.

As used here, the terms “operationally connected,” “operationallycoupled”, “operationally linked”, “operably connected”, “operablycoupled”, “operably linked,” and like terms, refer to a relationship(mechanical, linkage, coupling, etc.) between elements whereby operationof one element results in a corresponding, following, or simultaneousoperation or actuation of a second element. It is noted that in usingsaid terms to describe inventive embodiments, specific structures ormechanisms that link or couple the elements are typically described.However, unless otherwise specifically stated, when one of said terms isused, the term indicates that the actual linkage or coupling may take avariety of forms, which in certain instances will be readily apparent toa person of ordinary skill in the relevant technology.

For description purposes, the term “radial” is used here to indicate adirection or position that is perpendicular relative to a longitudinalaxis of a transmission or variator. The term “axial” as used here refersto a direction or position along an axis that is parallel to a main orlongitudinal axis of a transmission or variator. For clarity andconciseness, at times similar components labeled similarly (for example,stator assembly 200A and stator assembly 200B) will be referred tocollectively by a single label (for example, stator assembly 200).

Embodiments of a continuously variable transmission (CVT), andcomponents and subassemblies therefor, will be described now withreference to FIGS. 1-83. Referring now to FIG. 1, in one embodiment abicycle 1 can include a continuously variable transmission (CVT) 100supported in a frame 2. For simplification, only the rear portion of thebicycle 1 is shown FIG. 1. The frame 2 can include a set of dropouts 3that are configured to support the CVT 100. A sprocket 4 can couple tothe CVT 100, and the sprocket 4 further couples via a drive chain 5 to acrank sprocket 6. The crank sprocket 6 is typically coupled to a pedaland crank assembly 7. The CVT 100 can be coupled to a wheel 8 via anumber of wheel spokes 9. For clarity, only a few of the wheel spokes 9are shown in FIG. 1 as an illustrative example. In one embodiment, thetransmission ratio of the CVT 100 can be adjusted via cables and ahandle grip (not shown).

The CVT 100 can be used in many applications including, but not limitedto, human powered vehicles, light electrical vehicles hybrid human-,electric-, or internal combustion powered vehicles, industrialequipment, wind turbines, etc. Any technical application that requiresmodulation of mechanical power transfer between a power input and apower sink (for example, a load) can implement embodiments of the CVT100 in its power train.

Turning now to FIGS. 2 and 3, in one embodiment the CVT 100 includes ahub shell 102 coupled to a hub cover 104. The hub shell 102substantially surrounds the internal components of the CVT 100. A brakeadapter kit 106 couples to the hub shell 102. The CVT 100 can include anumber of planet subassemblies 108 supported in a carrier assembly 101.The planet subassemblies 108 couple to an input subassembly 110, whichinput subassembly 110 is generally depicted in detail view A). In someembodiments, the planet subassemblies 108 are operably coupled to thehub shell 102 via a traction ring 145. The traction ring 145 can beconfigured to engage a cam roller retainer assembly 147, which couplesto an output cam ring 149. The hub shell 102 couples to the output camring 149 in one embodiment. A main axle 112 can be arranged along thelongitudinal axis of the CVT 100 and can be coupled to, for example, thedropouts 3 with no-turn-washers 114, axle nut 116, and lock-nut 118. Inone embodiment, a shift rod 120 can be arranged along a central bore ofthe main axle 112 and can be coupled to an idler subassembly 109 via ashift nut 119. The idler subassembly 109 is arranged radially inward of,and in contact with, the planet subassemblies 108. The shift rod 120 canbe axially constrained in the main axle 112 via a shift-rod-lock nut122. In one embodiment, the shift rod 120 couples to, for example,cables (not shown) that are operationally coupled to a handlegrip oruser control interface (not shown). For descriptive purposes, thesprocket side of the CVT 100 can be referred to as the input side of theCVT 100, and the brake adapter kit 106 side of the CVT 100 can bereferred to as the output side of the CVT 100.

During operation of CVT 100, an input power can be transferred to theinput subassembly 110 via, for example, the sprocket 4. The inputsubassembly 110 can transfer power to the planet subassemblies 108 via atraction or friction interface between the input subassembly 110 and theplanet subassemblies 108. The planet subassemblies 108 deliver the powerto the hub shell 102 via the traction ring 145 and the output cam ring149. A shift in the ratio of input speed to output speed, andconsequently a shift in the ratio of input torque to output torque, isaccomplished by tilting the rotational axis of the planet subassemblies108. A shift in the transmission ratio involves actuating an axial orrotational movement of the shift rod 120 in the main axle 112, whichfacilitates the axial translation of the idler assembly 109 and therebymotivates the tilting of the rotational axis of the planet subassemblies108.

Passing now to FIG. 4, in one embodiment the input subassembly 110includes a torque driver 140 coupled to a torsion plate 142. The torsionplate 142 can be attached to a load cam ring 144 with, for example,screw fasteners or rivets. In some embodiments, the torsion plate 142can be coupled to the load cam ring 144 with a spline. In oneembodiment, the load cam ring 144 couples to a load cam roller retainersubassembly 146. The load cam roller retainer subassembly 146 furthercouples to a traction ring 148. The load cam ring 144, the load camroller retainer subassembly 146, and the traction ring 148 arepreferably configured to produce axial force during operation of the CVT100. In other embodiments, the load cam ring 144, the load cam rollerretainer subassembly 146, and the traction ring 148 are substantiallysimilar in function to the traction ring 145, the load cam rollerretainer 147, and the output cam ring 149 that are located on the outputside of the CVT 100.

Referring to FIGS. 5 and 6, in one embodiment the torque driver 140 canbe a substantially hollow cylindrical body with a first end having a setof torsion plate engagement splines 130 and a second end having a set ofsprocket engagement splines 132. In some embodiments, the torque driver140 can include a sprocket support shoulder 134 located on the outercircumference of the cylindrical body and axially positioned between thetorsion plate engagement splines 130 and the sprocket engagement splines132. In other embodiments, the second end can have a standard bicyclefreewheel thread to allow the coupling of a threaded freewheel orthreaded sprocket. A first bearing bore 136 can be provided on the innercircumference of the cylindrical body in proximity to the first end. Afirst bearing support shoulder 137 can be arranged on the innercircumference of the cylindrical body in proximity to the first bearingbore 136. A second bearing bore 138 can be provided on the innercircumference of the cylindrical body in proximity to the sprocketengagement splines 132. A second bearing support shoulder 139 can bearranged on the inner circumference of the cylindrical body in proximityto the second bearing bore 138. In some embodiments, the torque driver140 includes a number of service tool engagement splines 135 formed onthe inner circumference of the cylindrical body. The service toolengagement splines 135 can be arranged in proximity to the sprocketengagement splines 132 and can generally be accessible to the exteriorof the CVT 100.

Turning to FIGS. 7 and 8, in one embodiment the torsion plate 142includes a splined inner bore 170 and a number of triangular extensions172 extending radially from the splined inner bore 170. In someembodiments, the triangular extensions 172 are substantially axiallyaligned with a first end of the splined inner bore 170 so that thesplined inner bore 170 and the triangular extensions 172 form asubstantially flat face on the torsion plate 142. In other embodiments,the triangular extensions 172 extend from the splined inner bore 170 sothat the radially outward end of the triangular extension 172 is angledrelative to the splined inner bore 170 when viewed in the plane of thepage of FIG. 8. In one embodiment, each of the triangular extensions 172can be provided with a cutout 174. Each of the triangular extensions 172can be provided with a fastening hole 176 positioned on a radiallyoutward portion of the extension 172. The fastening holes 176 facilitatethe coupling of the torsion plate 142 to the load cam ring 144. Thesplined inner bore 170 facilitates the coupling of the torsion plate 142to the torque driver 140. The triangular extensions 172 provide alightweight and torsionally stiff structure to the torsion plate 142.The torsion plate 142 can be made from steel, aluminum, magnesium,plastic, or other suitable material.

Turning to FIGS. 9 and 10, in one embodiment the load cam ring 144 is asubstantially annular ring with a number of ramps 152 formed on a firstside of the annular ring. The load cam ring 144 can include a set ofpreload spring grooves 154, which can be formed on the first side of theannular ring. In some embodiments, the load cam ring 144 can have abearing support surface 158 formed on a second side of the annular ringthat is oppositely located from the first side of the annular ring. Inone embodiment, the load cam ring 144 can include a number of fasteninglugs 156 arranged on the inner circumference of the annular ring. Thefastening lugs 156 can be substantially axially aligned with the secondside of the annular ring. In some embodiments, the fastening lugs 156can be used to support an over-molded plastic torsion plate that issubstantially similar to torsion plate 142.

Referring to FIG. 11, the traction ring 148 can be a generally annularring having a number of ramps 153 formed on one side. The traction ring148 can be provided with a traction contact surface 1480 on the innercircumference of the annular ring that is substantially opposite theside having ramps 153. The traction contact surface 1480 is configuredto contact the planet subassembly 108. A number of preload springgrooves 155 can be formed on the annular ring. In one embodiment, thepreload spring grooves 155 are formed on the side having the ramps 153.In the embodiment shown in FIGS. 2 and 3, the traction ring 145 issubstantially similar to the traction ring 148.

Referring now to FIGS. 12-14, in one embodiment, an axial forcegenerator device includes, among other things, the load cam ring 144,the load cam roller retainer subassembly 146 and the traction ring 148.In one embodiment, the ramps 152 are arranged to contact a number ofload cam rollers 160. The load cam rollers 160 are retained in the loadcam roller retainer subassembly 146. A number of springs 162, forexample two, can be retained in the load cam roller retainer subassembly146 and can be arranged to simultaneously contact the load cam ring 144and the traction ring 148. In the embodiment illustrated in FIG. 13, theload cam roller retainer subassembly 146 includes a first slotted ring146A coupled to a second slotted ring 146B. In some embodiments, thefirst and second slotted rings 146A, 146B are received in a band 146C.The first slotted ring 146A and the second slotted ring 146B can beprovided with slots 164. The slots 164 are configured to support theload cam rollers 160. The first slotted ring 146A and the second slottedring 146B can be coupled together with, for example, a plurality of pegs166A and bores 166B. In some embodiments, each of the slotted rings 146Aand 146B have equally as many pegs 166A as bores 166B. The arrangementof the pegs 166A and the bores 166B around the face of the slotted rings146A and 146B can be configured to accommodate various manufacturingmethods, such as plastic injection molding. For example, the arrangementof the pegs 166A and the bores 166B can allow the slotted rings 146A and146B to be substantially identical for manufacture while retainingfeatures for alignment during assembly. In one embodiment, the pegs 166Aare arranged around half the circumference of the slotted ring 146Awhile the bores 166B are arranged around the other half of thecircumference. The arrangement of pegs 166A and 166B are substantiallysimilar on slotted ring 146B, so that once assembled the slotted rings146A and 146B are aligned when joined. In some embodiments, the slottedrings 146A and 146B are further retained around their outercircumference or periphery with the band 146C. The band 146C can be agenerally annular ring made from, for example, steel or aluminum. Anouter circumference of the band 146C can have a number of holes 167. Theholes 167 are generally aligned with the slotted rings 146A and 146B.The holes 167 are configured to, among other things, axially retain andalign the slotted rings 146A and 146B. In some embodiments, the slottedrings 146A and 146B can be coupled to the band 146C with standardfasteners (not shown) via fastening the holes 167. In other embodiments,the fastening holes 167 can receive mating features formed onto outerperiphery of the slotted rings 146.

Still referring to FIGS. 12-14, a plurality of springs 162, for exampletwo, are retained in load cam roller retainer subassembly 146 and arearranged in such a way that one end of the spring 162 couples to theload cam ring 144 and the other end of the spring 162 couples to thetraction ring 148. The springs 162 can be generally arranged 180-degreeswith respect to each other for configurations provided with two springs.In one embodiment, a middle portion of the spring 162 is retained in theload cam roller retainer subassembly 146. Shoulders 177 and 173 formedon the slotted rings 146A and 146B, respectively, can be provided tocapture the middle portion of the spring 162. In some embodiments, thespring 162 can be a coil spring of the compression type. In otherembodiments, the spring 162 can be a wire spring. In yet otherembodiments, the spring 162 can be a flat spring. It is preferable thatthe ends of spring 162 have rounded or curved surfaces that havegenerally the same shape as reaction surfaces 170 and 171.

A preload spring groove 154 can be formed onto the load cam ring 144.Similarly, a groove 155 can be formed onto the traction ring 148. Onceassembled, the preload spring grooves 154 and 155 aid to, among otherthings, retain the spring 162 and provide the reaction surfaces 170 and171, respectively. Channels 174 and 175 can be formed into the slottedrings 146A and 146B to provide clearance for the spring 162.

Preferably, once assembled, the springs 162 are configured to apply aforce on the load cam ring 144 and the traction ring 148 that engagesthe load cam rollers 160 with the load cam ring 144 and the tractionring 148. The load cam rollers 160 are positioned generally on the flatportion of the ramps 152 and 153. The interaction between the tractionring 148, the load cam ring 144, and the springs 162 causes the load camrollers 160 to roll up the ramps 152 and 153 for some distance toproduce a preload that ensures that a certain minimum level of clampingforce will be available during operation of the CVT 100.

Passing now to FIGS. 15A-15B, a torsion plate 1420 can include asubstantially disc-shaped body having a splined inner bore 1422configured to couple to, for example, the torque driver 140. The torsionplate 1420 can be provided with a bearing support surface 1424 on theouter periphery of one side of the disc-shaped body, and the torsionplate 1420 can be provided with a set of engagement splines 1426 locatedon the outer periphery of a second side of the disc-shaped body. Theengagement splines 1426 can be configured to engage a cam ring such ascam ring 144. In one embodiment, the torsion plate 1420 can include anumber of structural ribs 1428 arranged on the disc-shaped body. Thestructural ribs 1428 can form a lattice or triangulated pattern thatconnects the outer periphery of the disc-shaped body to the splinedinner bore 1422.

Referring to FIGS. 16A and 16B, a torsion plate 1600 can couple to aload cam ring 1602. The load cam ring 1602 and the torsion plate 1600can generally be used in CVT 100 in a similar manner as the load camring 144 and the torsion plate 142. In one embodiment, the torsion plate1600 can be a generally disc shaped body 1604 having a splined centralbore 1606. The splined central bore 1606 can be configured to mate withthe splines 130 of the torque driver 140, for example. An outerperiphery of the disc shaped body 1604 can be provided with a number ofsplines 1608. In some embodiments, the torsion plate 1600 can include anumber of structural ribs 1609 formed on a first side of the disc shapedbody 1604. The structural ribs 1609 can extend radially outward from thesplined central bore 1606 and can be configured in a substantiallytriangulated pattern, such as the pattern shown in FIG. 16A. Configuringthe structural ribs 1609 in this way can, among other things, improvethe torsional strength and stiffness to the torsion plate 1600.

The load cam ring 1602 can include a substantially annular ring 1610having a number of ramps 1612 formed on a first face. The ramps 1612 canbe substantially similar to the ramps 152. The inner circumference ofthe annular ring 1610 can be provided with a number of splines 1614 thatcan be adapted to mate with the splines 1608. In one embodiment, thetorsion plate 1600 can be made of a plastic material that is formed overthe load cam ring 1602. The splines 1608 and 1614 can be configured torigidly couple the torsion plate 1600 to the traction ring 1602. In oneembodiment, the annular ring 1610 can be provided with a bearing supportsurface 1616 that can be substantially similar to the bearing supportsurface 158. In some embodiments, the annular ring 1610 can include anumber of preload spring grooves 1618 that are substantially similar tothe preload spring grooves 155.

Turning to FIG. 17, in one embodiment the output cam ring 149 can be agenerally annular ring, substantially similar to the load cam ring 144.The output cam ring 149 can include a number of preload spring slots1492 arranged substantially similar to the preload spring slots 154. Theoutput cam ring 149 can also be provided with ramps 1494 that aresubstantially similar to ramps 152, and are configured to engage theload cam rollers 160. In one embodiment, the output cam ring 149includes lugs 1496 arranged on the inner circumference of the annularring. The lugs 1496 are preferably adapted to couple to a mating featureon the hub shell 102.

Referring now to the functional block diagram of FIG. 18, in oneembodiment a carrier assembly 50 can be configured to couple to, and/orto support, a planet subassembly 52. The carrier assembly 50 can befunctionally similar in some respects to the carrier assembly 101. Theplanet subassembly 52 can be functionally similar in some respects tothe planet subassembly 108. The carrier assembly 50 includes a statorinterfacial member 54 coupled to the stator support member 56. In oneembodiment, the stator support member 56 is further coupled to a statortorque reaction member 58. The stator interfacial member 54 can beconfigured to provide a sliding interface between certain components ofthe planet subassembly 52 and the stator support member 56. In oneembodiment, the stator interfacial member 54 is a component thatattaches to the stator support member 56. In some embodiments, thestator interfacial member 54 is integral with the stator support member56. In yet other embodiments, the stator interfacial member 54 isintegral with the planet subassembly 52. The stator interfacial member54 is preferably a low-friction interface and made from materials suchas plastic, bronze, or polished metals.

The stator support member 56 can be configured to provide structuralsupport for the carrier assembly 50, and the stator support member 56can be adapted to react forces generated during operation of the CVT100. The stator support member 56 positions and supports the planetsubassembly 52. The stator torque reaction member 58 can be provided totransfer torque from the stator support member 56 to another componentin, for example, the CVT 100 during operation of the CVT 100. In oneembodiment, the stator torque reaction member 58 is a component that canbe coupled to the stator support member 56 so that the stator torquereaction member 58 can be made from a different material than the statorsupport member 56. For example, the stator torque reaction member 58 canbe made of steel and the stator support member 56 can be made ofaluminum. It should be noted that the reference to steel and aluminumare exemplary only; in other embodiments, other materials can be used(such as, for example, plastics, alloys, ceramics, composites, etc.). Insome embodiments, the stator torque reaction member 58 is integral withthe stator support member 56. In yet other embodiments, the statorinterfacial member 54, the stator support member 56, and the statortorque reaction member 58 can be one integral component.

Turning now to FIGS. 19 and 20, the carrier assembly 101 can include afirst stator subassembly 200A coupled with a number of stator spacers202 to a second stator subassembly 200B. The stator spacers 202 can bearranged angularly around the perimeter of the stator subassemblies 200.In one embodiment, the stator spacers 202 can be attached to the statorsubassemblies 200 with common fasteners. In the embodiment shown in FIG.20, the stator spacers 202 are orbit formed on stator spacer ends 203for coupling the stator spacers 202 and the stator subassemblies 200.The carrier assembly 101 supports and facilitates a tilting of therotational axis of balls 240 of the planet subassemblies 108. In someembodiments, the carrier assembly 101 is configured to couple to themain axle 112. In one embodiment, for example, the carrier assembly 101is rigidly and non-rotatably coupled to the main axle 112.

Referring to FIGS. 21-27, the stator subassembly 200 can include astator torque reaction insert 204, a stator support member 206, and astator interfacial member 208. In one embodiment, the stator torquereaction insert 204 can be rigidly attached to the stator support member206, and the stator interfacial member 208 can be attached to the statorsupport member 206.

The stator torque reaction insert 204 facilitates the coupling of thecarrier assembly 101 to the main axle 112. In one embodiment, the statortorque reaction insert 204 includes a number of torque reactionshoulders 210 that are adapted to engage mating surfaces on the mainaxle 112. The stator torque reaction insert 204 prevents, among otherthings, rotation of the stator subassembly 200 with respect to the mainaxle 112. In one embodiment, the stator torque reaction insert 204 hassix torque reaction shoulders 210 that form a hexagonal body. A numberof locking splines 212 can be provided on the periphery of the hexagonalbody. The locking splines 212 can facilitate the rigid attachment of thestator torque reaction insert 204 to the stator support member 206.

In one embodiment, the stator support member 206 includes asubstantially disc-shaped body having an inner bore adapted to couple tothe stator torque reaction insert 204. In some embodiments, the statorsupport member 206 has an inner bore having a hexagonal shape. Thestator support member 206 can be provided with a number of spacersupport extensions 214 arranged angularly on a first face of thedisc-shaped body about the longitudinal axis of the CVT 100. The statorsupport extensions 214 are preferably positioned angularly about thelongitudinal axis of the CVT 100 and, for example, can be placedangularly between the planet subassemblies 108 in the CVT 100. In oneembodiment, each of the spacer support extensions 214 includes a statorspacer support hole 216. In some embodiments, the stator spacer supportholes 216 are arranged on a radially outward periphery of the statorsupport extensions 214. In one embodiment, each of the stator spacersupport holes 216 can be provided with a stator spacer end relief 217(see FIG. 25, for example). The stator spacer end relief 217substantially surrounds the stator spacer support hole 216. Onceassembled, the stator spacer end 203 is substantially enclosed in thestator spacer end relief 217. The arrangement of stator spacers 200 onthe outward periphery of the stator support extensions 214 maximizestorsional stiffness of the carrier assembly 101. The stator supportmember 206 can be provided with a number of structural ribs 218 arrangedon a face of the disc-shaped body. The structural ribs 218 providestrength and stiffness to the disc-shaped body. The stator supportmember 206 provides structural support to the carrier assembly 101 forreacting forces generated during the operation of, for example, the CVT100.

Referring to FIGS. 21-27, the stator support member 206 can be furtherprovided with a number of guide support slots 220. The guide supportslots 220 are substantially arranged between the spacer supportextensions 214 around the disc-shaped body and extend radially outwardfrom the inner bore. The number of guide support slots 220 provided onthe stator support member 206 generally, though not necessarily,corresponds to the number of planet subassemblies provided in the CVT100. Each of the guide support slots 220 can be provided with a legclearance relief 222A positioned on a radially inward portion of theguide support slot 220. The leg clearance reliefs 222A provide clearancefor certain components of the planet subassembly 108 during operation ofthe CVT 100. In some embodiments, the stator support member 206 caninclude a piloting shoulder 224 located radially inward of the guidesupport slots 220 and spacer support extensions 214. The pilotingshoulder 224 facilitates alignment of the stator support member 206 tothe stator interfacial member 208. In some embodiments, the statorsupport member 206 can have a uniform material thickness throughout thecomponent, which aides manufacturing processes such as casting orforging.

In one embodiment, the stator interfacial member 208 is a substantiallydisc-shaped body having an inner bore. The stator interfacial member 208can be provided with a number of sliding guide slots 226 arrangedangularly about a longitudinal axis of the disc-shaped body. Thedisc-shaped body can include a number of interlocking tabs 228 formed onone side. The interlocking tabs 228 are configured to mate with a numberof interlocking holes 229 on the stator support member 206. In someembodiments, a number of leg clearance reliefs 222B are formed towardthe inner periphery of the guide slots 226. The stator interfacialmember 208 can be provided with a capture ring 230 formed on the outerperiphery of the disc-shaped body. The capture ring 230 is preferablyformed on the side of the disc-shaped body with the interlocking tabs228. The capture ring 230 can couple to a capture shoulder 231 formed onthe stator support member 206. The interlocking tabs 228 and capturering 230 facilitate a rigid coupling between the stator interfacialmember 208 and the stator support member 206. A number of captureextensions 232 (see FIG. 26) can be provided on the outer periphery ofthe stator support member 206. The capture extensions 232 are generallyconcentric with the capture shoulder 231 and are configured to couple tocapture cavities 233 (FIG. 27) of the stator interfacial member 208. Inone embodiment, the stator interfacial member 208 can be a plasticcomponent, and can be pressed onto the stator support member 206 so thatthe capture ring 230 and the interlocking tabs 228 engage thecorresponding mating capture shoulder 231 and the interlocking holes229. In some embodiments, the stator interfacial member 208 can beplastic injection molded onto the stator support member 206. The statorinterfacial member 208 facilitates a low friction, sliding couplingbetween the carrier assembly 101 and the planet subassemblies 108.

Turning now to FIGS. 28-29, the planet subassembly 108 can include asubstantially spherical ball 240, a ball axle 242, and at least one leg244. The ball 240 can be provided with a central bore. The ball 240 issupported on the ball axle 242 with ball support bearings 249 arrangedin the central bore and positioned with spacers 245A, 245B, and 245C. Inother embodiments, the spacers 245A, 245B, and 245C can be integral withthe ball support bearings 249. The ball axle 242 can be supported on oneend with one leg 244 and on a second end with another leg 244. In someembodiments, the leg 244 can be pressed onto the ball axle 242 so thatthere is no relative motion between the leg 244 and the ball axle 242during operation of the CVT 100. The legs 244 can be configured to actas levers to pivot the ball axle 242 about the center of the ball 240.

Referring to FIGS. 30-32, in one embodiment the leg 244 includes asliding interface 246 and a shift cam guide end 248. The leg 244 can beprovided with a ball axle support bore 250. In some embodiments, the leg244 can include a hole 252. The hole 252 can serve to, among otherthings, reduce the weight of the leg 244. In one embodiment, the slidinginterface 246 can have a length L1 of about 12.5 mm and a width W1 ofabout 8 mm. In some embodiments, a leg 2444 can be substantially similarin function to the leg 244. The leg 2444 can be provided with a slidinginterface 2466 that can be of a length L2 that can be about 7 mm, forexample. The shift cam guide end 2488 can have a width w2, which isgenerally about 3.5 mm. The shift cam guide ends 248 and 2488 arepreferably adapted to slide on the shift cams 260 (see FIG. 20, forexample). The sliding interfaces 246 and 2466 are preferably adapted toslide in the carrier assembly 101. In some embodiments, the slidinginterfaces 246 and 2466 have curved profiles as shown in the plane ofthe page of FIG. 31 or FIG. 32. Each of the curved profiles of thesliding interfaces 246 and 2466 are typically conformal to a matingsurface of the carrier assembly 101. The legs 244 or 2444 are preferablyadapted to transfer forces from the planet subassembly 108 to thecarrier assembly 101.

Passing now to FIGS. 33-34, an alternative carrier assembly 300 includesa number of stator interfacial inserts 302 supported in a stator supportmember 304. The stator interfacial inserts 302 are slidingly coupled tolegs 240 of the planet subassemblies 108. The carrier assembly 300includes a retaining ring 306 configured to couple the statorinterfacial inserts 302 to the stator support member 304. In oneembodiment, the carrier assembly 300 includes two stator support members304 rigidly coupled together. Preferably, each leg 240 of the planetsubassemblies 108 is provided with a corresponding stator interfacialinsert 302. It should be readily apparent to a person having ordinaryskill in the relevant technology that the carrier assembly 300 issubstantially similar in function to the carrier assembly 101.

Referring to FIGS. 35-38, the stator support member 304 can be agenerally cylindrical body having a central bore. The stator supportmember 304 can include a number of insert support slots 308. The insertsupport slots 308 can be arranged angularly about, and extend radiallyfrom, the central bore of the cylindrical body. Preferably, though notnecessarily, the stator support member 304 has at least one insertsupport slot 308 for each stator interfacial insert 302. Each of theinsert support slots 308 can have a tab engagement hole 310 formed on aradially inward portion of the insert support slot 308. The tabengagement hole 310 can be configured to couple to a mating feature onthe stator interfacial insert 302. The stator support member 304 can beprovided with a number of support extensions 312. Each of the statorsupport extensions 312 includes a fastening hole 314 and a dowel pinhole 315; each hole is configured to receive a fastener and a dowel pin,respectively. In one embodiment, the fastening hole 314 is arrangedradially inward of the dowel pin hole 315. The stator support member 304can be provided with a number of cutouts 316 formed on one end of thecylindrical body. Preferably, the cutouts 316 reduce the weight of thestator support member 304 while retaining the strength and stiffness ofthe component. In one embodiment, the stator support member 304 can havea number of torque reaction shoulders 318 formed on the inner bore. Thetorque reaction shoulders 318 can be adapted to mate with correspondingshoulders on the main axle 112. In some embodiments, the torque reactionshoulders 318 form a square bore. In one embodiment, the stator supportmember 304 is provided with a retaining ring groove 320 that isconfigured to couple to the retaining ring 306.

Turning now to FIGS. 39-42, the stator interfacial insert 302 can be agenerally rectangular body having a back 322 with at least two sideextensions 324 attached to the back 322. A stator interlock tab 326 canbe formed on the back 322. In one embodiment, the stator interlock tab326 can be substantially circular and extend from the back 322. Thestator interlock tab 326 can be configured to couple to the tabengagement hole 310 on the stator support member 304. In one embodiment,the stator interfacial insert 302 includes a retaining shoulder 328formed on an end of the back 322 at a distal location from the statorinterlock tab 326. The retaining shoulder 328 is configured to couple tothe retaining ring 306. In other embodiments, a stator interfacialinsert 303 is not provided with a retaining shoulder such as theretaining should 328, but can share many other similar elements with thestator interfacial insert 302.

The stator interfacial insert 302 can be provided with a sliding guidesurface 330 formed between the two side extensions 324. The slidingguide surface 330 is preferably adapted to couple to a leg 240 of theplanet subassembly 108. In one embodiment, the sliding guide surface 330has a leg clearance recess 332 formed on an end of the rectangular bodyin proximity to the stator interlock tab 326. The stator interfacialinsert 302 preferably is made from a low-friction material withsufficient compressive strength. For example, the stator interfacialinsert 302 can be made out of a variety of plastics that can includeFortron 1342L4, Nylon 6/6 resin, Vespel, Rulon, PEEK, Delrin or othermaterials. The materials listed here are merely examples and are notintended to be an exhaustive list of acceptable materials as manydifferent types of materials can be used in the embodiments disclosedherein.

Passing now to FIGS. 43-44, in one embodiment a carrier assembly 400includes a stator support member 402 coupled a stator torque reactioninsert 404, which can be substantially similar to the stator torquereaction insert 204. The stator support member 402 is adapted toslidingly couple to a number of planet subassemblies 406. Preferably,the carrier assembly 400 includes two stator support members 402 coupledto each other with common screw fasteners, rivets, or welds.

Referring to FIGS. 45-46, in one embodiment the stator support member402 is a substantially bowl-shaped body having a central bore. Thestator support member 402 can include a fastening flange 410 having anumber of fastening holes 411. The fastening flange 410 can be arrangedon the outer periphery of the bowl-shaped body. A number of guidesupport slots 412 can be formed on the interior of the bowl-shaped body.The stator support member 402 can be provided with a number of ballclearance cutouts 414 configured to substantially surround each of theplanet subassemblies 406. The stator support member 402 can include anumber of torque reaction shoulders 416 formed on the central bore ofthe bowl-shaped body. In one embodiment, the torque reaction shoulders416 form a hexagonal pattern. The torque reaction shoulders 416 can beadapted to couple to the stator torque reaction insert 404. The statorsupport member 402 can be provided with a number of structural ribs 418arranged on the bottom of the bowl-shaped body. The structural ribsprovide strength and stiffness to the stator support member 402.

Referring to FIGS. 47 and 48, in one embodiment the planet subassembly406 includes a ball 420, a ball axle 422, and a leg 424. The ball 420has a bore and is supported on the ball axle 422 with support bearings426. In one embodiment, the support bearings 426 are positioned in onthe ball axle 422 with at least one spacer 428. The leg 424 can bepressed onto an end of the ball axle 422. Each end of the ball axle 422is coupled to a leg 424. In one embodiment, the leg 424 includes asliding interface guide 421, a shift cam engagement surface 423, and abearing support extension 425 surrounding a ball axle bore 427. In someembodiments, the leg 424 can include a press relief hole 429 arrangedconcentric with the ball axle bore 427. The sliding interface guide 421can have a curved profile when viewed in the plane of the page of FIG.48. The sliding interface guide 421 is preferably substantiallyconformal with the guide support slots 412 so that the forcestransferred from the leg 424 to the stator support member 402 aredistributed over a large surface area of contact between the leg 424 andthe stator support member 402. This arrangement minimizes stress andwear on the contacting components.

Turning to FIGS. 49-50, in one embodiment a shift cam 430 includes anumber of leg contact surfaces 432. The leg contact surfaces 432 canhave a profile that is substantially convex when viewed in the plane ofthe page in FIG. 50, and the profile can be substantially flat whenviewed in the plane of the cross-section in FIG. 49. The substantiallyflat profile facilitates a line contact between the leg 424 and theshift cam 430. The line contact is preferable for minimizing wear andstress on the leg 424 and the shift cam 430. In one embodiment, theshift cam 430 includes a number of alignment extensions 436. Thealignment extensions 436 are arranged on each side of each of the legcontact surfaces 432, so that the leg 424 is substantially flanked bythe alignment extensions 436 when assembled. In some embodiments, theshift cam 430 is provided with a bearing race 438 that is adapted tosupport a bearing for facilitating the coupling of the shift cam 430 to,for example, the idler assembly 109. The shift cam 430 can also beprovided with a shift nut engagement shoulder 440 that extends axiallyfrom the leg contact surfaces 432. The shift nut engagement shoulder 440surrounds a hollow bore 442, which is configured to provide clearance tothe main axle 112, for example. The shift nut engagement shoulder 440can couple to the shift nut 119, for example.

Passing now to FIGS. 51-56, in one embodiment a carrier assembly 500 caninclude a stator support member 502 coupled to a stator interfacialmember 504. A stator torque reaction insert 506 can be coupled to theinner bore of the stator support member 502. The stator support member502 can be provided with a number of torque reaction shoulders 507 (seeFIG. 53, for example). The torque reaction shoulders 507 are configuredto engage a number of mating torque reaction shoulders 508 provided onthe stator torque reaction insert 506. In one embodiment, the statortorque reaction insert 506 includes a piloting flange 510 that extendsradially from the torque reaction shoulders 508. The piloting flange 510is adapted to align and couple to the inner diameter of the statorinterfacial member 504. In some embodiments, the piloting flange 510 caninclude a number of holes (not shown) configured to receive fasteners,such as rivets, to facilitate the coupling of the piloting flange 510 tothe stator support member 502. In other embodiments, the piloting flange510 can be welded to the stator support member 502. In yet otherembodiments, the piloting flange 510 can be configured to couple to thestator support member 502 via the stator interfacial member 504. Forexample, the stator interfacial member 504 can be made of plastic, whichcan be formed around the piloting flange 510 and the stator supportmember 502 in such a way as to facilitate the coupling of the pilotingflange 510 to the stator support member 502.

Referring now specifically to FIGS. 53-54, the stator support member 502can be a generally bowl shaped body having a bottom face 512. In oneembodiment, the torque reaction shoulders 507 are formed on the bottomface 512. It should be readily apparent that the torque reactionshoulders 507 can be, in some embodiments, knurls or splines (not shown)configured to facilitate the coupling of the stator support member 502to, for example, the main axle 112. A number of interlock cavities 514can be provided on the bottom face 512. The interlock cavities 514 areadapted to couple to mating features located on the stator interfacialmember 504. In the embodiment shown in FIGS. 53 and 54, the interlockcavities 514 are arranged in groups of four interlock cavities 514 perplanet assembly 108, and the groups of interlock cavities 514 aredistributed angularly about the torque reaction shoulders 507 on thebottom face BF. In one embodiment, each of the interlock cavities 514has a corresponding tab 515 that extends from the interlock cavity 514towards the interior of the bowl shaped body. The tabs 515 areconfigured to align and couple to mating features of the statorinterfacial member 504. The stator support member 502 can also beprovided with a number of ball clearance cavities 516 formed on theouter periphery of the bowl shaped body. The number of ball clearancecavities 516 preferably, though not necessarily, corresponds to thenumber of planet subassemblies 108 provided in, for example, the CVT100. The stator support member 502 can include a fastening flange 518located on the outer periphery of the bowl-shaped body. The fasteningflange 518 can have a number of fastening holes 519. In one embodiment,the stator support member 502 can be a stamped sheet metal component.Once assembled, carrier 500 can include two stator support members 502coupled together at the respective fastening flange 518 with commonscrew fasteners or rivets.

Referring to now specifically to FIGS. 55 and 56, the stator interfacialmember 504 can include a disk shaped body having an inner bore. In oneembodiment, the disc shaped body has a number of guide slots 520arranged angularly about the inner bore so that each of the guide slots520 extends radially from the inner bore to an outer periphery of thedisc shaped body. In some embodiments, the guide slots 520 have aconformal profile configured to couple to the legs 240 of the planetassembly 108. The stator interfacial member 504 can include a number ofinterlock tabs 522 configured to mate with the interlock cavities 514and tabs 515 of the stator support member 502. In one embodiment,interlock tabs 522 can be arranged in groups of four interlock tabs 522located at each guide slot 520. For example, each of the guide slots 520can be flanked on each side by at least two interlock tabs 522. In someembodiments, at least one interlock tab 522 is arranged on either sideof the guide slot 520. The stator interfacial member 504 can be providedwith a number of leg clearance slots 524. The leg clearance slots 524are generally formed on the inner circumference of the disk shaped bodyand the leg clearance slots 524 are substantially aligned angularly withthe guide slots 520. In some embodiments, the stator interfacial member504 can include a number of stator support member extensions 526 thatare configured to engage the stator support member 502. The statorsupport member extensions 526 are preferably substantially aligned with,and extend from, the guide slots 520.

Referring now to FIGS. 57-62, in one embodiment a carrier assembly 600can include a first stator support member 602 coupled to a second statorsupport member 603 via a number of stator spacers 604. The carrierassembly 600 can be adapted to cooperate with planet subassemblies 406.The first stator support member 602 can be a generally disk-shaped bodyhaving a central bore 608. The central bore 608 is configured to coupleto, for example, the main axle 112. In one embodiment, the main axle 112is welded to the first stator support member 602, for example. In otherembodiments, the main axle 112 can be coupled to the first statorsupport member 602 via torque reaction shoulders that are substantiallysimilar to torque reaction shoulders 210 (see FIG. 21, for example) andthe torque reaction shoulders 318 (see FIG. 35, for example).

Still referring to FIGS. 57-62, the second stator support member 603 canbe a generally disc-shaped body having a central bore 610. The centralbore 610 is configured to provide clearance between the disc-shaped bodyand the main axle 112. In one embodiment, the radial clearance betweenthe disc-shaped body and the main axle 112 is large enough to allow theidler assembly 109, for example, to be removed from the main axle 112while the second stator support member 603 and the first stator supportmember 602 remain assembled. The radial clearance between the secondstator support member 603 and the main axle 112 facilitates, among otherthings, angular alignment between the first and second stator supportmembers 602 and 603 that is independent from the alignment of the mainaxle 112 to the second stator support member 603, thereby simplifyingassembly of the carrier 600 and the main axle 112.

In one embodiment, the first stator support member 602 is provided witha number of support extensions 612 and a number of guide slots 614interposed between the support extensions 612. The guide slots 614 arearranged angularly about, and extend radially from, the central bore608. The planet assemblies 406 are adapted to slide in the guide slots614. The support extensions 612 substantially define the perimeterstructure for a number of stator spacer cavities 616. Each of the statorspacer cavities 616 is adapted to receive an end of the stator spacer604. The end of the stator spacer 604 can attach to the stator spacercavity 616 with common screw fasteners, press fit, or other suitablefastening means. Similarly, the second stator support member 603 can beprovided with the support extensions 612. The support extensions 612form sides for the guide slots 614. The guide slots 614 are arrangedangularly about, and extend radially from, the central bore 610. Thesupport extensions 612 substantially define the perimeter structure fora number of stator spacer cavities 616.

In one embodiment, the stator spacer 604 includes ends 620 and 622connected by a clearance neck 624. The clearance neck 624 is preferablyconfigured to maximize torsional stiffness of the stator spacers 604while maintaining adequate clearance between the planet subassemblies406. In one embodiment, the clearance neck 624 has a substantiallydiamond shaped cross-section 626 at the mid-point of the body while theends 620 and 622 are substantially triangular in cross-section, whenviewed in the plane of the page of FIG. 62.

Turning to FIG. 63, in one embodiment the main axle 112 can include asubstantially elongated body with a shift nut clearance slot 1120arranged in a middle portion of the elongated body. The shift nutclearance slot 1120 is an opening in the elongated body that is alignedaxially in the elongated body. The shift nut clearance slot 1120 has afirst axial end and a second axial end. A number of torque reactionshoulders 1122 can be formed in proximity to each axial end. In oneembodiment, six torque reaction shoulders 1122 are formed at the firstaxial end, and six torque reaction shoulders 1122 are formed at thesecond axial end. In some embodiments, only four torque reactionshoulders 1122 are formed at each axial end. In other embodiments, asfew as one torque reaction shoulder 1122. In yet other embodiments, thetorque reaction shoulders 1122 can be a knurled surface. The torquereaction shoulders 1122 are configured to couple to, for example, thecarrier assembly 101. The main axle 112 can also include frame supportflats 1124 on each end of the elongated body. The frame support flats1124 are configured to couple to, for example, dropouts 3 (see FIG. 1,for example).

Referring to FIG. 64 now, a shift nut 119 can include a threaded bore1190 configured to couple to the shift rod 120, for example. The shiftnut 119 can include at least two shift cam engagement faces 1192 thatextend from the threaded bore 1190. The shift cam engagement faces 1192can be substantially flat surfaces that are configured to couple to, forexample, the shift cam 430. In one embodiment, the shift nut 119 can beprovided with a bore 1194 that intersects the threaded bore 1190. Thebore 1194 can, among other things, reduce the weight of the shift nut119.

Passing now to FIGS. 65A-66, in one embodiment an idler assembly 700includes an idler 702, a first and a second shift cam 704 and 706operably coupled to the idler with a bearing 705. In some embodiments,the bearing 705 has a flexible cage 707 that can be manipulated duringassembly. In other embodiments, the bearing 705 can consist of twobearings that have independent cages. The idler assembly 700 can becoupled to, for example, the shift rod 120 with a first and a secondshift nut 708A and 708B. The shift nuts 708 can be arranged in the shiftnut clearance slot 1120 of the main axle 112 and couple to shift nutengagement shoulders 710 formed on the shift cams 704 and 706. The shiftnut 708 can be provided with a threaded bore 712 adapted to couple to athreaded portion of the shift rod 720. The shift nut 708 can beconfigured to axially translate with a rotation of the shift rod 120,and thereby axially translating the idler assembly 700. In oneembodiment, the shift nut 708 is provided with a shift cam engagementshoulder 714 formed on a first end. The shift cam engagement shoulder714 is configured to mate with the shift nut engagement shoulders 710.The shift cam engagement shoulder 714 extends radially in one directionfrom the threaded bore 712 and is aligned axially with the first end ofthe body of the shift nut 708. In some embodiments, the shift nut 708 isprovided with a set of flats 716.

During assembly, the first and the second shift nuts 708 are placed inthe shift nut clearance slot 1120 and positioned to allow the idlerassembly 700 to be placed onto the main axle 112. In some embodiments,the first and the second shift nuts 708 are one integral component. Oncethe idler assembly 700 is placed onto the main axle 112, the shift rod120 is threaded into the first shift nut 708A, which aligns the threadedbore 712 with the longitudinal axis of the transmission and facilitatesthe engagement of the shift cam engagement shoulder 714 with the shiftnut engagement shoulder 710. The second shift nut 708B is threaded ontothe shift rod 120 and couples to the second shift cam 706. Onceassembled, the two shift nuts 708 axially guide the idler assembly 700.The shift nuts 708 allow the idler assembly 700 to be removed from themain axle 112 without disassembly of the idler assembly 700.

Turning to FIGS. 67-69, one embodiment of the hub shell 102 will bedescribed. The hub shell 102 can include a first spoke flange 6700A anda second spoke flange 6700B arranged on the outer periphery of the hubshell 102. The first and the second spoke flanges 6700 are provided witha number of spoke fastening holes 6702 to facilitate the coupling of theCVT 100 to a wheel of a bicycle, for example. The hub shell 102 caninclude a number of brake adapter splines 6704 formed on an exteriorsurface of the hub shell 102. The brake adapter splines 6704 areencircled with a set of threads 6706. The threads 6706 are configured tomate with a brake adapter ring 7300 (see FIG. 3, for example). A secondset of threads 6708 are provided on an end opposite the brake adaptersplines 6704. The second set of threads 6708 are configured to mate withthe hub shell cover 104. The hub shell 102 can be provided with aninterior face 6710 having a central bore concentric with the brakeadapter splines 6704. The central bore can include a seal bore 6712, abearing bore 6714, and a snap ring groove 6716. Preferably, the sealbore 6712 is positioned axially outward of the bearing bore 6714. Theseal bore 6712 is configured to support, for example, an axle seal. Thebearing bore 6714 is configured to support, for example, a bearing. Theinterior face 6710 can be provided with a set of splines 6718 configuredto mate with the output cam ring 149, for example.

Referring to FIGS. 70-72 now, one embodiment of the hub cover 104includes a disc-shaped body 7000 having a central bore 7002, an exteriorface 7004, and an interior face 7006. The interior face 7006 ispreferably arranged facing the interior of the CVT 100, and the exteriorface 7004 is preferably arranged facing the exterior of the CVT 100. Insome embodiments, the hub cover 104 is arranged on the input side of theCVT 100. The hub cover 104 includes a threaded outer periphery 7008configured to mate with the hub shell 102. The central bore 7002 can beprovided with a bearing support surface 7010 and a seal support bore7012. The bearing support surface 7010 and the seal support bore 7012are coaxial with the main axle 112. The interior face 7006 can beprovided with a thrust reaction surface 7014 configured to support, forexample, a thrust bearing of the CVT 100. The hub cover 104 can beprovided with a set of stiffening ribs 7016 extending radially from thecentral bore 7002 on the interior face 7006. In some embodiments, thehub cover 104 includes a set of tool engagement splines 7018 arranged onthe exterior face 7004 and surrounding the central bore 7002. The toolengagement splines 7018 facilitate, among other things, the coupling ofthe hub cover 104 to the hub shell 102.

Passing to FIGS. 73-74, in one embodiment a brake adapter ring 7300 canbe a generally annular ring having a threaded perimeter 7302. A firstexterior face of the annular ring can include a number of toolengagement holes 7304 configured to facilitate the coupling of the brakeadapter ring 7300 to, for example, the hub shell 102. The brake adapterring 7300 can be provided with a locking chamfer 7306 formed on theinner circumference of the annular ring. In some embodiments, thediameter of the annular ring is in the range of 1.25 to 3.25 inches.

Referring to FIGS. 75-76 now, in one embodiment a disc brake adapter7500 includes a brake alignment surface 7502 and a number of torquereaction splines 7504. The brake alignment surface 7502 is substantiallyconfigured to mate with a standard disc brake for a bicycle. The torquereaction splines 7504 are configured to mate with the brake adaptersplines 6704 of the hub shell 102 (see FIG. 67, for example). The discbrake adapter 7500 can be provided with a seal support surface 7506 thatis configured to couple to a seal of the CVT 100. A number of brakefastening holes 7508 can be provided on the disc brake adapter 7500. Thedisc brake adapter 7500 can include a locking chamfer 7510 configured toengage the brake adapter ring 7300. The engagement of the lockingchamfer 7510 with the locking chamfer 7306 provides a rigid couplingbetween the disc brake adapter 7500 and the hub shell 102.

Referring now to FIGS. 77-79, in one embodiment a roller brake adapter7700 can include a number of torque reaction splines 7702 that aresubstantially similar to torque reaction splines 7504, and areconfigured to couple to the brake adapter splines 6704 of the hub shell102. The roller brake adapter 7700 can be provided with a splinedextension 7704 that is configured to couple to a standard roller brakeof a bicycle. The roller brake adapter 7700 can include a lockingchamfer 7706 that is substantially similar to the locking chamfer 7510,and is adapted to engage the locking chamfer 7306 of the brake adapterring 7300. The roller brake adapter 7700 can also be provided with aseal support surface 7708 that is configured to couple to a seal of theCVT 100. Once assembled, the roller brake adapter 7700 can be coupledto, for example, the CVT 100 at substantially the same location on thehub shell 102 as the disc brake adapter 7500. The engagement of thelocking chamfer 7706 with the locking chamfer 7306 provides a rigidcoupling between the roller brake adapter 7700 and the hub shell 102. Inone embodiment, the brake adapter kit 106 can include the brake adapterring 7300 and the disc brake adapter 7500. In other embodiments, thebrake adapter kit 106 can include the brake adapter ring 7300 and theroller brake adapter 7700.

Turning now to FIGS. 80 and 81, in one embodiment a carrier assembly 800can include a first stator support member 802A coupled with a number ofstator spacers 804 to a second stator support member 802B. The statorspacers 804 can be arranged angularly around the perimeter of the statorsupport members 802. In one embodiment, the stator support members 802and the stator spacers 804 are substantially similar in function to thestator subassemblies 200 and the stator spacers 202. The carrierassembly 800 supports and facilitates a tilting of the rotational axisof a number of planet subassemblies 806. In some embodiments, the statorsupport member 802 can be coupled to a stator torque reaction insert 807that is substantially similar to the stator torque reaction insert 204,for example. In other embodiments, the stator support member 802 iscoupled directly to the main axle 112.

Turning to FIGS. 82 and 83, and still referring to FIGS. 80 and 81, inone embodiment, the planet subassembly 806 includes a first statorinterfacial cap 808A coupled to a first leg 810A. The planet subassembly806 includes a ball 812 configured to rotate about a planet axle 814. Inone embodiment, the planet axle 814 is supported in the first leg 810Aand in a second leg 810B. The second leg 810B can be coupled to a secondstator interfacial cap 808B. Typically, each of the stator interfacialcaps 808 are provided with a planet axle relief 816 that is configuredto provide clearance between the planet axle 814 and the statorinterfacial cap 808. The stator interfacial cap 808 preferably includesa sliding interface surface 817 that is configured to contact the statorsupport member 802. In one embodiment, the sliding interface surface 817has a curved profile when viewed in the plane of the page of FIG. 81.The sliding interface surface 817 is substantially similar in certainfunctional aspects to the sliding interface guides 421. In someembodiments, the stator interfacial cap 808 includes sides 818 thatextend from the sliding interface surface 817. The sides 818 can bearranged to substantially flank the leg 810. In some embodiments, thestator interfacial caps 808 are made of a plastic or other low-frictionmaterial. The legs 810 can be made of steel, for example. The statorinterfacial cap 808 can be formed or assembled onto the legs 810 via aplastic molding process, for example. Once assembled, the statorinterfacial cap 808A and the leg 810 can be substantially similar incertain functional aspects to the leg 244, 2444, or 424, for example. Insome embodiments, the leg 810 can be adapted to couple to the shift cam260 or 430, for example.

It should be noted that the description above has provided dimensionsfor certain components or subassemblies. The mentioned dimensions, orranges of dimensions, are provided in order to comply as best aspossible with certain legal requirements, such as best mode. However,the scope of the inventions described herein are to be determined solelyby the language of the claims, and consequently, none of the mentioneddimensions is to be considered limiting on the inventive embodiments,except in so far as anyone claim makes a specified dimension, or rangeof thereof, a feature of the claim.

The foregoing description details certain embodiments of the invention.It will be appreciated, however, that no matter how detailed theforegoing appears in text, the invention can be practiced in many ways.As is also stated above, it should be noted that the use of particularterminology when describing certain features or aspects of the inventionshould not be taken to imply that the terminology is being re-definedherein to be restricted to including any specific characteristics of thefeatures or aspects of the invention with which that terminology isassociated.

What we claim is:
 1. A transmission comprising: a plurality of planetassemblies arranged angularly about, and on a plane perpendicular to, alongitudinal axis of the transmission, each planet assembly having aleg; a plurality of stator interfacial inserts arranged angularly aboutthe longitudinal axis, wherein each leg is configured to slidinglycouple to each of the stator interfacial inserts; and a stator supportmember mounted coaxially with the longitudinal axis, the stator supportmember configured to couple to each of the stator interfacial inserts.2. The transmission of claim 1, further comprising an axle arrangedalong the longitudinal axis and coupled to the stator support member. 3.The transmission of claim 1, wherein the stator support membercomprises: a generally cylindrical body having a central bore; aplurality of insert support slots arranged angularly about, andextending radially from, the central bore; and a plurality of statorsupport extensions arranged coaxial with the plurality of insert supportslots, the stator support extensions arranged angularly about thecentral bore, wherein each of the stator support extensions has afastening hole and a dowel pin hole.
 4. The transmission of claim 3,wherein the central bore comprises a plurality of torque reactionshoulders.
 5. The transmission of claim 4, wherein each of the statorsupport extensions comprise a plurality of cutouts.
 6. The transmissionof claim 1, wherein each stator interfacial insert comprises a generallyrectangular body having a back, a first side extension, and a secondside extension.
 7. The transmission of claim 6, wherein each statorinterfacial insert comprises a sliding guide surface located between thefirst and second side extensions.
 8. The transmission of claim 7,wherein each stator interfacial insert comprises a leg clearance recessformed on an end of the rectangular body between the first and secondside extensions.
 9. The transmission of claim 8, wherein the generallyrectangular body is made at least partly from a plastic material.
 10. Astator support member for a continuously variable transmission (CVT),the stator support member comprising: a generally cylindrical bodyhaving a central bore; a plurality of insert support slots arrangedangularly about, and extending radially from, the central bore; and aplurality of stator support extensions arranged coaxial with theplurality of insert support slots, the stator support extensionsarranged angularly about the central bore, wherein each of the statorsupport extensions has a fastening hole and a dowel pin hole.
 11. Thestator support member of claim 10, wherein the central bore comprises aplurality of torque reaction shoulders.
 12. The stator support member ofclaim 10, wherein each of the stator support extensions comprise aplurality of cutouts.
 13. The stator support member of claim 10, furthercomprising a stator interfacial insert coupled to each insert supportslot.
 14. The stator support member of claim 13, wherein the statorinterfacial insert comprises a generally rectangular body having a back,a first side extension, and a second side extension.
 15. The statorsupport member of claim 14, wherein the stator interfacial insertcomprises a sliding guide surface located between the first and secondside extensions.
 16. The stator support member of claim 15, wherein thestator interfacial insert further comprises a leg clearance recessformed on an end of the rectangular body between the first and secondside extensions.
 17. The stator support member of claim 16, wherein thegenerally rectangular body is made at least partly from a plasticmaterial.
 18. A stator interfacial insert for a continuously variabletransmission, the stator interfacial insert comprising: a generallyrectangular body having a back, a first side extension, and a secondside extension; a stator interlock tab formed on the back; and a slidingguide surface located between the first and second side extensions. 19.The stator interfacial insert of claim 18, further comprising a legclearance recess formed on an end of the rectangular body between thefirst and second side extensions.
 20. The stator interfacial insert ofclaim 18, wherein the generally rectangular body is made at least partlyfrom a plastic material.